Automated forming of non-refrigerated molded food products

ABSTRACT

NON-REFRIGERATED FOOD PRODUCTS FORMED BY FEEDING A CONGLOMERATE FOOD MIX IN PLASTIC STATE TO THE MOLDS OF AN AUTOMATED MOLDING EQUIPMENT OF A TYPE CONVENTIONALLY USED TO FORM FROZEN CONFECTIONS. THE FOOD MIX IS CHARACTERIZED BY AN ESSENTIALLY SOLID STATE AT ROOM TEMPERATURE AND A PLASTIC STATE WHEN HEATED ABOVE ABOUT BODY TEMPERATURE. THE MIX TYPICALLY INCLUDES AS BASIC INGREDIENTS FRAGILE, PARTICULATED FOOD SOLIDS AND AN UNCOOKED BINDING AGENT. FEEDING OF THE MIX TO THE EQUIPMENT MOLDS IS BY NONDESTRUCTIVELY INJECTING MEASURED AMOUNTS OF THE MIX THROUGH NOZZLE MEANS CYCLICALLY RECIPROCATED INTO AND WITHDRAWN FROM THE MOLDS. AFTER SOLIDIFICATION OF THE MOLDED ARE BRIEFLY HEATED AND THE PRODUCTS WITHDRAWN FROM THE MOLDS. IF DESIRED, THE FORMED PRODUCTS WHILE STILL COLD CAN BE PROVIDED WITH A HIGH GLOSS DIP COATING.

June l, 19.71 B. E. RAsMussoN AUTOMATED FORMING NON-REFRIGERATED MOLDED FOOD PRODUCTS 6 Sheets-Shut 1 Filed June 7, 1966 RY m5 I N VEN 'l OR. BEN 5. RAsMasoA/ Mmmm A r Toen/EVS' O June l; :1971 B. E. RAsMUssoN vAUTOMATIEJD FORMING NON-REFRIGERATED MOLDED FOOD -PRODUCTS Filed June 7.

6 Sheets-Sheet 5 Il :15:5: f fr June l, 1971 B. E. RAsMussoN 3,582,349

AUTOMATED FDRMING NON-REFRIGERATED MOLDED FooD PRODUCTS Filed June 7, 1966 6 Sheets-Sheet 4 A rive/V945 June l, 1971 a. E. RAsMussoN AUTOMATED FORMING NONnREFRIGERATED MOLDED FOOD PRODUCTS Filed June '7, 1966 6 Sheets-Sheet 5 June l, 1971 B. E. RASMUSSON AUTOMATED FORMING NON-REFRIGERATED MOLDED FOOD PRODUCTS Filed June '7. 1966 6 Sheets-Sheet 6 VHIIIIIL kwk MQ QQQS@ w United States Patent O AUTOMATED FORMIN G OF N ON-REFRIGERATED MOLDED FOOD PRODUCTS Ben E. Rasmusson, 915 1st Ave. S., Kent, Wash. 98031 Continuation-impart of application Ser. N0. 654,058, July 18, 1967. This application June 7, 1966, Ser.

Int. Cl. A23g 3/00, 3/ 02 U.S. Cl. 99-1 12 Claims ABSTRACT F THE DISCLOSURE Non-refrigerated food products formed by feeding a conglomerate food mix in plastic state to the molds of an automated molding equipment of a type conventionally used to form frozen confections. The food mix is characterized by an essentially solid state at room temperature and a plastic state when heated above about body temperature. The rnix typically includes as basicl ingredients fragile, particulated food solids and an uncooked binding agent. Feeding of the mix to the equipment molds is by nondestructively injecting measured amounts of the mix through nozzle means cyclically reciprocated into and withdrawn from the molds. After solidiiication of the molded products by rapid cooling of the molds, the molds are briefly heated and the products withdrawn from the molds. If desired, the formed products while still cold can be provided with a high gloss dip coating.

CROSS REFERENCES TO RELATED APPLICATIONS A related continuation-in-part application 654,058, entitled Food Products Comprised of Oil- Milk-Sugar Clad Cereal Particles and Method of Making Same, was filed luly 18, 1967. Related divisional application Ser. No. 792,598, and entitled Food Dispensing Apparatus, was filed on Jan. 21, 1969. Related divisional application Serial No. 792,326, entitled Food Molding Machine and Associated Filling Mechanism, was filed on Jan. 21, 1969.

The present invention relates in general to the automated forming of non-refrigerated food products such as confections and the like on equipments conventionally used to form stick-embedded frozen confections, such as the type of equipment known as the Vitaline. Facets of the invention also relate to unique feeder mechanisms for delivering measured amounts of a plastic conglomerate food mix to the molds of such equipments. Other aspects of the invention relate to the particularized operating conditions for such equipments, whereby such are adapted for automated formation of non-refrigerated molded products. Still other aspects of the invention relate to various novel molded food products formed by practice of the operating techniques herein disclosed.

Embedded stick type frozen confections are now commonly manufactured on a variety of equipments, such as the Vitaline, Gram, Nelson and Polarmatic equipments. In general, these equipments conventionally involve delivery of a liquid mix into molds, then freezing of the mix in the molds in a cooling section, with the frozen products being released from the molds by brief heating of the molds, the formed frozen confections then being withdrawn from the molds by means of withdrawal of the sticks embedded therein.

At present, many such frozen confection making equipments are used only seasonally in that the market for frozen confections is seasonal to a great extent. A basic object and purpose of the present invention is to provide equipment and operating modifications whereby such equipments need not be idle during the off-season and can ICC be employed to full capacity any time not needed for production of frozen confections, to manufacture non-refrigerated food products on an automated basis. It is a further object and purpose of the present invention to provide a feeder mechanism for use in conjunction with automated food product molding equipments, which is capable of non-destructively feeding measured amounts of a conglomerate plastic mass of a food composition, even if the composition includes fragile particles such as puffed or toasted cereals, nut meats, or the like. It is a further object and purpose of the present invention to provide various food porducts formed on automated mold type forming equipment which are in general characterized by a solid state at room temperature and which exhibits plastic flow at temperatures at and above about body temperature. More particularly, certain of such food products are characterized by the presence of a preponderant quantity of solid or semi-solid food particles such as dried cereals, dried fruits, freeze-dried fruits, nuts, nut meats, grains, puffed grains, pre-cooked meat, and the like, together with an uncooked fluid binding agent which is liquid above about body temperature and solid at room temperature, which may be composed of a mixture including selected vegetable oils having a flow point of about 96 F., liquid slurries of reconstituted |milk solids, flours, starches, sugar and/or cocoa, with lecithin stabilizers, hydrolized yeast, emulsiers, flavoring and the like, the binding agent being present in suicient quantity to coat each food particle at least lightly. Various types of food products are contemplated for manufacture according to the present invention; namely (l) cookie type products wherein the particulated food particles include puffed or aerated cereals, and in which the binder can be so-called confectioners compound coating having a melting point of about 96 F. or slightly higher; (2) candy type products wherein the solid particles are pre-formed candies, marshmallows or creams, together with the indicated binding agent; (3) candy type products with or without included solid particles, such as nougats and fondants; (4) parlor snacks, wherein the food particles are meat, bread, grains, nuts and the like and in which the binder may be hydrogenated vegetable oils in combination with flours, starches, stabilizers and the like; (5) so-called heatand-eat snacks, wherein the particulated food particles are pre-cooked meat particles with a fluid Ibinder which may be vegetable oils, aqueous slurries of reconstituted egg solids, starches or gums, or the like; and (6) raw, uncooked meats wherein the fluid binder is the natural meat juices, either alone or in combination with an added iluid binder such as above recited in connection with precooked meat mixes.

It is a particular object of the present invention to provide a technique of molding and coating non-refrigerated food products with a chocolate or like coating, wherein the coating is applied to the molded product in cooled state and solidiies quite rapidly (e.g. in 15-20` seconds), yet is glossy in appearance and exhibits excellent quality of appearance even after extended storage at room temperature, which technique is in contrast to the con-v ventional practice in the candy industry of slow solidification of chocolate coating over a period of several minutes (e.g. about 6 minutes), as heretofore considered necessary in order to obtain a good gloss and avoid bloomlng, streaking or greying of the coating during storage at room temperature.

It'is a further object and advantage of the present in- Ventron to provide a feeder mechanism for repetitively delivering multiple amounts of a plastic conglomerate mass to associated receptacle means therefor, such as the successively presented banks of molds of a conventional frozen confection forming machine, which feeder mechanism incorporates means for maintaining'the conglomerate mix in a condition of plastic flow, means for segregating and enclosing a measured amount of the mix, means for injectively delivering the enclosed amount of mix from associated nozzle means into the receptacle means, and movement sequence controlling means which can be cyclically operated either independently or in timed relation to an associated equipment such as a conventional frozen confection forming machine.

It is a related object of the feeder mechanism of the present invention to have the capability of automatically and successively feeding measured amounts of a conglomerate mix, wherein the conglomerate mix is plastic or semi-solid in nature and contains fragile food particles such as puffed or toasted cereals, nut meats or the like, without substantial destruction or compression of the fragile particles, and to effect such feeding at high throughput rates consistent -with the production speeds normally attainable by conventional molded food product forming equipment.

It is a related and more specific object and advantage of the present invention to provide feeder mechanism for plastic food mixes, particularly solid particle entrained plastic food mixes, wherein the feeder mechanism comprises a reciprocating plunger assembly on carriage means in turn cyclically reciprocated to cause nodzle means associated with such plunger assembly to physically enter into and be progressively withdrawn from mold type receptacle means during each mix injection cycle of the nozzle means.

These and other objects, features and advantages of the present invention will be apparent from the following description, appended claims and annexed drawing.

Referring to the drawing -wherein like reference characters designate like parts throughout the several views:

FIG. l is a somewhat schematic side elevational view of a typical assemblage of equipment for practicing the process of the present invention, such equipment including a mixer arranged to discharge into a feeder which in turn is arranged to discharge into the traveling molds of a conventional automated frozen stick confection machine, such view constituting a flow diagram for the process of the present invention;

FIG. 2 is aview of a preferred form of feeder, constituting a facet of the present invention, with some parts thereof appearing in side elevation, and with other parts thereof appearing in vertical section, taken substantially along line A-A of FIG. 5, such view showing both the nozzle carriage and the piston assembly in retracted positions relative to the molds of the frozen stick confection machine;

FIG. 3 is a view similar to FIG. 2, with the piston assembly still retracted, but with the nozzle carriage fully extended, so as to place the nozzles relatively deeply into a set of molds in position to be filled;

FIG. 4 is a view similar to FIGS. 2 and 3, but showing the nozzle carriage in a stage of retraction and the piston assembly in a stage of extension;

FIG. 5 is a top plan view of the feeder, with certain foreground portions thereof broken away for the purpose of exposing certain other portions of the feeder which are normally shielded from view by such foreground portions, and with the hopper being shown in oblique section, taken substantially along line 5-5 of FIG. 2;

FIG. 6 is a sectional view taken through the feeder perpendicularly to the plane of nozzle movement, and substantially along line B-B of FIG. 2, such view showing the reciprocatory valve plate in an open position and some of the mix in the piston cavities, into which it had gravitated;

FIG. 7 is a view ysimilar to FIG. 6, but showing the valve plate in a closed position, and a measured amount of the food mixture trapped in each piston cavity;

FIG. 8 is a schematic diagram of a typical pneumatic operating and control system for the feeder;

FIG. 9 is a fragmentary View of a bottom portion of the hopper, showing another form of piston, of split or forked form, a central island member that is secured to and movable with the nozzle carriage, and mounts a -secured displacement needle for forming a cavity in the molded product;

FIG. 10 is a fragmentary side elevational View of the assembly of FIG. 9, showing both the piston and the nozzle in their extended positions;

FIG. 11 is a view taken from the same aspect as FIG. 9, but of only the nozzle region of FIG. 9, such view showing the forked piston in a stage of retraction, and further showing the split or forked construction of the nozzle and a modiled form of displacement needle;

FIG. l2 is a view of a stick confection manufactured according to the present invention by equipment including a feeder equipped with nozzle and piston means of the type depicted by FIGS. 9-11;

FIG. 13 is a schematic diagram of a typical pneumatic operating and control system for the feeder mechanism illustrated.

In FIG. l a conventional Vitaline Model 6 frozen confection forming machine (selected by way of example to illustrate typic'al practice of the invention) is generally designated at V and includes a main conveyor assembly comprising a laterally spaced pair of main conveyor chains C which carry a series of product forming molds M, the molds M being arranged in laterally extending sets or banks 4of six molds each. Main conveyor chains C, moving stepwise in the direction indicated at d, conventionally move the molds progressively past one or more feeders or fillers F through a brine tank T wherein the liquid mix in the molds is frozen, with sticks being inserted into the partially frozen molds from a stick inserter S in the course of the mold travel through the brine tank T. With the frozen confection mix frozen in the molds M at the end4 of the course of travel thereof through the brine tank T, vertically reciprocated defrost tank means R heats the molds and releases the molded products from the molds M, and the molded products are separated from the molds M by an associated vertically reciprocated extractor bar E engaging the embedded sticks and lifting the products out of the molds M by movement of the extractor bar E through an upward stroke. The extractor bar carrying the sticks and formed products then meshes into an extractor bar conveyor G which then moves the formed products to an optional and conventional dip coater station I and then to an optional dry coater station I, which suitably can involve a dry coater such as disclosed and claimed in my U.S. Pat. No. 3,307,517. At the discharge end of the extractor bar conveyor G in the upper conveyor section of the equipment, the products are released from the extractor bars by a tripping mechanism (not shown), whereupon the products fall into bags in a bagger assembly B and are thereafter conveyed to a packaging station P.

In general terms, to the extent such need be now considered for an understanding of the method aspects of the present invention, there is also shown in FIG. l, a plastic or semi-solid food product mixer A and feeder F. Mixer A comprises a heated, screw conveyor type blender 12 mixing solid ingredient inputs from dispensers D1, D2, D3 with the fluid binder ingredients being delivered through conduit 20, the resulting mix being discharged to heated hopper 2'2 of the feeder F. Feeder F in turn also comprises a bank of outlet nozzles 66 through which the mix is multiplicately discharged into the successive banks of molds M of the Vitaline machine V.

The specific construction and manner of operation of the mixer A and feeder F', which collectively can also be termed a mixing zone, are discussed in more detail in the portion of this description following the discussion of the method of the invention, as next presented.

Plastic or conglomerate food product mixes utilized in practice of the invention characteristically include as part thereof certain particulated solids and also an uncooked fluid binding agent which is in solid state at room ternperature and which is in iluid state when heated to temperatures at and above about body temperature. Considered collectively, the food product mix selected to illustrate an operating example of the method aspects of the invention includes what may be termed a milk mix portion and a solids mix portion, wherein the milk mix contains the following constituents:

26.0# vegetable oils (flow point 96 F.) 28.8# sucrose sugar 14.6# non-fat milk solids 0.4# avoring (vanilla) 0.2# lecithin 70.0# total and wherein such solids mix contains the following:

20.0# crisp rice (expanded).

The above milk mix, typical of what is known in the trade as Confectioners Compound Coating, was heated to a controlled temperature of about 100 F., and pumped into the inlet conduit 20 of the mixer A and the solids mix was metered into the mixer A -by feed from the hoppers D1, D2, D3 thereof, with all portions of the mixer A being maintained at a temperature of about 110 F. to 130 F. Delivery of the mixed ingredients from the mixer A to the feeder F by action of conveyor 12 is regulated to maintain the level of the mix in the hopper 22 of the feeder F at a desired level, and the mix retaining elements of the feeder F in contact with the mix are in like manner maintained at au elevated temperature of about l110 F. to about 130 F. so that the conglomerate mix as it is discharged from the nozzles 66 into the molds M of the Vitaline equipment is in a heated condition, and at a temperature in the range of from about 100 F. to about 130 F.

The feeding apparatus F is synchronously operated in conjunction with the Vitaline equipment, as discussed in detail hereinafter, principally in connection with the sequencing control diagrams presented at FIGS. 8 and 13, with the result that each of the molds M is substantially lled with the plastic conglomerate food product mix, being in effect injected or extruded thereinto by the feeder F. Progressive operation of the Vitaline equipment then conveys each successive mold bank into the brine tank T which is maintained at a temperature suitable for the selected production rate of the equipment. As a practical matter, the cooling temperature encountered by the molds M and the brine tank T need not be below freezing, but is optimally below freezing at about minus 10 F. for example, for realizing optimum product production rates. Experimentation has shown that the soliditication or setting time of the above-selected conglomerate food mix, in relation to the temperature in the brine tank T, has been observed to be as follows for molds having a volume of three iluid ounces.

Temperature F.): Mix solid (min.)

72 (room temp.) After-.. 20 55 (water cooling) do l0 40 (chilled water) do 8 30 (brine cooling) do 6 (brine cooling) do 5 (brine cooling) do 4 -30 (brine cooling) do 3 minutes. With a standard 18 foot brine tank T as conlventionally employed in the Vitaline model 6, the solidified molded food products are retained in the cooling section of the equipment longer than the 4 minutes indicated, and it will be readily understood that such equipment could either be shortened or the speed of operation thereof increased, with corresponding increase in production, if desired. In an actual production run during which the solidified products course the brine tank T and emerge therefrom approximately 7'1/2 minutes after filling, and with hot water circulating through the defrost tanks R at about F.130 F., the formed products were released frorn the molds M in like manner as is characteristic of frozen product release, and then manipulated through the dip coating station H heated to F., wherein a chocolate compound coating (formulated with fractionated cocoanut oil) was applied, after which -an air jet was directed briefly down around each formed product to remove the excess coating. Because of the latent and relatively low temperature of the formed products the coating solidified quickly, i.e. within 15-25 seconds. Prior to complete solidiiication of the dip coating, a dry coating of nut meats or the like can be applied at dry coater station I, following which the formed products are discharged to bagger B and packaging station P in the usual manner.

Referring again to FIG. 1, the mixer A is schematically shown to include an elevated trough 10. The end of trough 10 distal the feeder F is closed, and the opposite end, which is proximal and `above the feeder F', is open. An elongated rotary, ribbon screw type blender 12 is located in the trough 10, and is supported for rotation by means including a shaft 14. The shaft 14 is shown to project through, and extend outwardly beyond, the closed end of trough 10. The shaft 14, and in turn the blender 12, may be rotated by a motor 16, drivingly connected to the projecting end portion of the shaft 14 by a chain and sprocket or belt and pulley transmission 18, for example. The blender 12 comprises both mixing paddles and cut-folded screw vanes adapted to move the mixture from the closed to the open end of the trough 10, as illustrated.

In at least most cases, the binder ingredient exists as a solid at room or ambient temperature and melts at a temperature substantially above ambient. As previously explained, the binder ingredient is heated until it is a liquid or at least a ilowable plastic capable of mixing with and adhering to the usually dry particulate material. While in such liquid or fiowable plastic state, the binder ingredient is delivered to the trough 10 by a conduit 20, and may be merely spilled into the trough 10, near the closed end thereof. The principal particulate ingredient, which may be dry puffed grain particles, fo-r example, may be dispensed in measured amounts into the trough 10 by means of a dispenser D1 having a discharge portion situated closely adjacent the outlet end of conduit 20. A suitable dispenser D1 includes a hopper and a vibrator unit or an equivalent mechanism for moving the material from the hopper into the trough 10. Additional dispensers D2, D3 of the same or similar type may be used for delivering additional particulate ingredients into the trough, as will hereinafter be explained in some detail.

The trough 10 includes hollow wall portions (i.e. a jacket) through which hot water or steam may be circulated for the purpose of maintaining the ingredients at a proper temperature and consistency for mixing, and for maintaining the resulting mix in a flowable plastic state. As illustrated, the mix may merely spill out from the open end of trough 10 and free fall into the hopper 22 of the feeder F'.

In some installations it may be desirable to locate the trough 10, the feed pipe 22 and the dispensers D1, (and D2, D3, etc.) down close to the floor, so that they can be tended by an operator standing on the floor. In such installations the mix would be caught -at the discharge end of trough 10 by a suitable elevating means, adapted for elevating and dumping the mix into the hopper 22 of the feeder F.

The feeder F is an accessory for, but is preferably a self-contained unit separate from, the frozen confection forming machine, whether it be a Vitaline type machine V or a different type. The feeder F is shown to include its own floor supported base 28 and a transfer mechanism supported by said base 28. The base 28 includes wheels or casters 30, so that it can be easily rolled into and away from its position of use. Preferably, it also includes a set of vertically adjustable anchor legs 32. As will be evident, the legs 32 are adjusted to be above the floor when it is desired to use the castetrs. Then, when it is desired to tix the feeder F in position, the legs 30 are adjusted downwardly so that they contact the floor and the casters are lifted above the oor.

The feeding mechanism F will now be specifically described. The hopper 22 is shown to be secured to, and to extend above, a reciprocating nozzle carriage 34. Carriage 34 includes a relatively thick plate 36 which serves as the bottom for the hopper 22, and is formed to include a plurality of feed rams or piston cavities 38 equal in number to number of molds M in each mold set or bank of the Vitaline machine V. The disposition or attitude of plate 36 is such that each ram cavity 38 is coaxially related to an associated mold M at the filling station of the Vitaline machine V.

By -way of typical and therefore non-limitive example, the nozzle carriage 34 is shown to be supported for reciprocal movement relative to its frame 40 by means of a pair of track and roller assemblies. In FIGS. 2-4, 6 and 7 the tracks are shown to be formed by the lower flanges 42 of a pair of channel members 44 secured along the side marginal portions of the plate 36. The rollers 46 are supported by short axles secured to the side Walls 48 of the frame 40.

The carriage 34 is reciprocated by a piston-cylinder type uid motor 50. In the illustrated embodiment, the cylinder 512 is secured to a xed strut 54 interconnected between the walls 48 below the carriage 34, and the piston 56 is secured to a support plate 58 which in turn is secured to, and depends below, the carriage plate 36.

As previously mentioned, and as illustrated by FIGS. 2-7, the ram cavities 38 are preferably recesses formed in the upper part of the carriage plate 36. The cavities 38 are shown to be generally rectangular in cross-section, and to each be in parallelism with the others. A at rectangular bar 60 bridges across the cavities 38 at the nozzle end of the carriage, and a similar bar 62 bridges lacross the cavities 38 at the opposite end of the carriage. The hopper 22 may be secured to the carriage by a plurality of bolts, some of which are designated 64. These bolts extend first through front and rear lower ange portions `63, 65 of the hopper 22, then through the bridge plates 60, 64, and then anchor in the carriage plate 36.

A nozzle 66 is associated with each ram cavity 38. The nozzles 66 have flanged base portions which are secured to the front edge portion of the carriage plate 36, such as by bolts (not shown). Each nozzle possesses a central passageway which is substantially identical in cross-sectional size and shape to the tunnel portions of its cavity 38, below the bridge bars 60, 62.

As best shown by FIGS. 2, 4 and 5, the side rails or channels 44 of the carriage extend rearwardly a substantial distance (and in parallelism) from the carriage plate 36, and are interconnected at their rear ends by a transverse cross tie 68, also shown to be of channel form. The channels 44, in their extent rearwardly of the carriage plate 36, and the rear channel 68 together define a closed frame which supports and guides a reciprocating feed ram assembly.

`Referring specifically to FIGS. 2-5, the feed ram assembly is shown to comprise a rear placed transverse tie bar 70. A sliding guide block 72 is secured at each end of the tie bar and is sized to t snugly between the upper and lower flanges of the channels `44. The tie bar 70 constitutes a rear mount for a set of rains 74. Each ram 74 is sized to snugly lit within its recess 38, including in the tunnel areas thereof, below the bridge bars 60, 62. The rams 74 are long enough so that the forward portions thereof are always retained in the rear tunnel areas below the rear bridge bar 62, even Iwhen the ram assembly is in its rearmost position. The rear portion of each ram 74 may be secured to the tie bar 70 by a single bolt 76, for example.

The rams 74 are reciprocally moved axially through the cavities 38, and relative to the carriage, by means of a piston-cylinder type iluid motor 78. In the illustrated embodiment (FIGS. 2-4, for example), the cylinder 80' is secured to a central lower bottom portion of the carriage plate 36, and the piston 82 is secured to a lower central portion of the tie bar 70.

As best shown by FIGS. 5 and 6, the cavities 38 are of upwardly opening channel form; they are open topped and open into the hopper 22. A closure plate 86 is provided to close the open tops of the cavities 38 during the periods of piston advancement. Plate 86 has a continuous border portion and includes a generally rectangular, closed ended cutout for each cavity 38. Plate 86 is of substantially the same thickness as the bridge bars `60, 62, and is mounted for reciprocal movement transversely of the cavities 38, in the space defined front to rear by the bridge bars 60, 62 and below by the carriage plate 36. An exposed end portion of plate 86 projects outwardly from a side tunnel area formed vertically by carriage 36 and a side ange 88 of hopper 22. Plate 86 is reciprocated by a piston-cylinder type =uid motor 90, comprising a cylinder 92 secured to the free end of a support arm 94, which in turn is cantilevered from channel 44 (FIG. 7), and a piston 96 secured to a central edge portion of the plate 86.

The border portions 86' of plate 86, and the bar portions 98 thereof between the cutouts, form individual closures for the cavities 38. Such closures may have beveled side edges that slope inwardly from the bottom up, so as to form entrances into the cutouts which are wider than the top openings of the cavities 38, for the purpose of facilitating gravitation of the mix into cavities 38. A lixed closure bar 100 may be secured between hopper 22 and carriage plate 36.

FIG. 6 shows the piston 96 retracted, the closure bars 98, 86 positioned over the ridge or raised portions of plate 36, situated between the recesses 38, and the cutout in plate 86 aligned with the recesses 38, and forming funnel-like entrances therefor. FIG. 7 shows the piston 96 extended and the closure bars 98, 86' in closed position over the cavities 38.

Hopper 22 is provided with heater means for maintaining the mix therein at a proper temperature and consistency for injection or extrusion through the nozzles y66. Preferably, the heating means is incorporated in both the walls and bottom of the hopper 22. in FIGS. 2-7, 9 and 10, the walls of hopper 22 are shown to be in water jacket form; they comprise spaced apart panels 22', 2 dening an innerspace between them through which a heated fluid, e.g. hot water or steam is circulated. Carriage plate 36 is shown to include passageways 37 for a circulating heated uid medium. Alternatively, electric heating means may be incorporated into the walls of the hopper 22 and/or the carriage plate 36. Also, an immersed type of heater may be used.

In operation of the equipment above described, a heated binder material (e.g. of a type that is solid at room temperature and melts at about body temperature) is delivered through conduit 20 into trough 10 and admixed therein with fragile particles of a solid or semisolid food substance (e.g. dried cereals) delivered into trough 10 by one or more of the dispensers D1, D2, D3. The blending screw 12 folds the components of the mix, and in that manner mixes them thoroughly, but does not crush the solid or semi-solid food particles. In this respect, the nonrestricted discharge of the mix from trough is important. Since the outlet of trough 10 is in no rway restricted, no back pressure is developed which would tend to resist movement of the mix toward such outlet, and hence compaction and crushing of the fragile solid or semi-solid particles is avoided. i

Feeder F also handles and dispenses the mix in a way such that there is no compaction and substantially no crushing of the solid or semi-solid particles. The mix freely gravitates into the recesses 28. Valve plate 98 does not crush the solid or semi-solid particles as it moves because the mix is free to move with it. The nozzle passageways are at least the same size as the recesses 38. Thus, when the pistons 74 are extended they do not force the mix against converging nozzle walls which would create a back pressure and cause come compaction of the mix and crushing of the fragile particles. Rather, the nozzle passageways present only frictional resistance to the mix, and such resistance is nominal.

The typical and therefore nonlimitive form of operational and control circuitry illustrated by FIG. 8 will now be described. The basic Vitaline equipment typically ernploys a pneumatic control system, including an advancedwell control valve 102, shown schematically by a box diagram (and identified as slave valve No. 3 in the pneumatic system schematic diagram for Models 6 and 8 found in the 6-5-63-75 Vitaline Model 6 Service Manual published by Vitafreze Equipment, Inc., Sacramento, Calif) During the initial portion of dwell periods of the mold carrying conveyor C, valve 102 communicates air supply line 104 iwith a control line 106, extending from valve 102 to the operators (not shown) of the components or optional accessories of the Vitaline machine which operate during the conveyor dwell periods, such as the defrost apparatus, the stick insertion cylinder, the conventional Vitaline liquid mix filler (designated F in FIG. 1), and a dry coater. During the final portion of the conveyor dwell periods, and during movement of the conveyors, valve 102 vents control line 106 to the atmosphere, via an exhaust port 108.

The illustrated form of pneumatic operation and control circuitry for the feeder F includes a supply conduit 110 leading from a source of compressed air, such as a main trunk 112 leading from an air compressor (not shown). Supply conduit 110 includes an off-on valve 114, a variable orifice, regulated pressure controlled, pressure regulator 116, a vapor trap 118, and an oiler 120.

In FIG. 8 the pistons 56 and 82 of carriage actuator 50 and feed ram actuator 78, respectively, are shown in extended positions, and piston 96 of closure plate actuator 78 is shown in a retracted position. This corresponds to the positions of these parts shown in FIGS. 2 and 6, and places the feeder carriage 34 in its retracted position, back away from the fill station of the Vitaline machine V, the feed rams 74 in retracted positions, and closure plate 86 in its piston-cavity open position.

At the start of a dwell period of the Vitaine mold conveyor C, pressurized air from Vitaline line 106 is communicated via feeder control line 122 with the left end (as pictured) of spool 124 of control valve 126. The opposite end of spool 124 is subjected to atmospheric pressure, the communication to atmosphere being made through control line 128 and exhaust port 130 of a first limit valve 132. The higher pressure in line 122 moves spool 124 to the right (as pictured), communicating supply conduit 110 with the rod side of piston 56 in cylinder 52. The opposite or bare side of piston 56 is vented to the atmosphere via control line 134 and exhaust port 136 of valve 126. As piston 56 moves to the left (as pictured), and is retracted into its cylinder 52, the ller carriage is extended, placing nozzles 66 in the molds M then at the ll station of the Vitaline machine.

When ller carriage 34 is in its retracted position it contacts and depresses operator 138 of a limit valve 140 10 forming a part of a safety interlock circuit. Valve is in series in the Vitaline signal circuit which supplies pressurized air to cause advancement of mold conveyor C. As long as operator 138 is depressed Vitaine control line 144 is in communication (through valve 140) with the Vitaline control line 144, and the Vitaline advance signal circuit is completed. However, iwhen operator 138 is released it moves upwardly, shuts olf communication between lines 142 and 144, and vents line 142 to the atmosphere via exhaust port 146. As long as line 142 is vented to the atmosphere, the control means that would advance the Vitaline conveyor C is inoperative. Hence, advancement of the Vitaline conveyor C is prevented until the ller carriage 34 once again returns to its retracted (i.e. FIG. 2) position.

When liller carriage 34 is fully extended, and nozzles 66 are in the molds M, the carriage 34 contacts and depresses operator 148 of limit valve 132. This communicates supply manifold 110 With control liine 128 leading to the right end (as pictured) of valve spool 124. At this point of time, the Vitaline advance-dwell valve 102 has functioned to vent control line 106, 122 to the atmosphere, and thus valve spool 124 is moved to the left by the higher pressure in control line 128.. This puts control line 151 and the rod side of piston 56 in communication with the atmosphere through exhaust port 152, and both the bare side of piston S6 and the rod side of piston 82 are put in communication with the supply manifold 110 via control lines 134, 150, respectively. As a result, the filler carriage 34 commences to back up or retract at the same time the feed pistons or rams 74 commence to advance, resulting in the mix being fed into the molds M concurrently with nozzle withdrawal from the molds M (FIG. 4).

As the piston carriage 70, 74 leaves its retracted position it relases operator 156 of limit valve 158, putting control line 160 in communication with the atmosphere via exhaust port 162 of valve 158, and blocking flow into valve 158 via supply manifold 110. At this point both ends of valve spool 164 of control valve 166 are vented to the atmosphere. The pressure on spool 164 is equalized, and it stays to the right side of valve 116 in the position illustrated.

When the feed ram assembly 70, 74 reaches the end of its advancement, it contacts and depresses operator 168 of limit valve 170. As opera-tor 168 moves inwardly it functions to communicate supply manifold 110' with control line 172, and in turn the right end of valve spool 154, at a time when the left-hand side thereof is still vented to the atmosphere. Valve spool 164 is moved to the left by the pressure differential, resulting in supply manifold 110 being put into communication with control line 174 leading to the rod side of piston 9'6, and control lines 176, 178 being vented to the atmosphere via exhaust port of valve 166. Piston '96 is retracted and moves closure plates 86 to a cavity open position (FIG. 7). The piston cavities are closed during advancement of the rams 74, retraction of the fill carriage, and dispensing or extrusion of the mix.

As illustrated, control lines 134, 150, 151, 174, 176 and 1718 are provided with variable orifice ow regulators 184, 1185, 186, 187, 188 and 190, respectively. Control line 174 is vented to the atmosphere through exhaust port 182 of valve 166 when spool 164 is positioned as illustrated. Filler control lines 122, 1142 and 144 may be connected to their corresponding parts of the Vitaline circuitry by coupling means 192, 194, 196, respectively.

In the feeder embodiment of IFIGS. 2-8 the feed rams 74 can be advanced substantially completely through ythe nozzles y'66. Feed rams 74 are preferably constructed of metal except at the free ends thereof, whereat a Teflon or similar plastic tip is provided. Such end portion may be secured to the free ends of the pistons in the same manner as the portions of the split pistons illustrated by FIGS. 9- 11, and described below.

Referring now to FIGS. 9-11, the various feeder parts illustrated thereby are in most respects the same as those illustrated by and described in conjunction with FIGS. 1- 8, with the exception of the construction and operation of the feed rams.

The feed rams 74' are of split or forked construction, and comprise at least a pair of tines 198, 200. The space between the tines 1918, 200 is filled by a spacer or island member 202 that is secured to the carriage plate 36. In this form the nozzles 66 are shorter than the nozzles `66, and enter only a short distance into the molds M. However, the fixed island member 202 mounts a tapered prong 204 which does enter a substantial distance into the mold M. The prong 204, which is preferably fabricated from or coated with a non-sticking material such as Teflon, functions to prevent a complete filling of the mold M by the mix from hopper 22, so that a cavity remains, where prong 204 once was, after such prong is withdrawn from the mold M. This cavity is then later filled by a different but compatible food composition, as will hereinafter be explained in greater detail.

Cavity forming prong 204 may be of a gradually tapering rectangular form, as illustrated by FIGS. 9 and 10, o1' it may be of a gradually tapering rounded form (FIG. ll). Also it need not be centrally located, as illustrated, and a plurality of prongs may be provided. For securing it to the island member 202, the prong 204 (or prongs) may include a threaded root 205 mateable with a threaded soc-ket formed in the end of member 202. The free ends of the tines 198, 200, may be providedl with plastic tips 1918', 200', e.g. Teflon, and such tips 198, 200 may be secured to the tines 198, 200 by a locking mortise and tenon joint, for example.

A typical pneumatic control and operation system for the feeder F (FIGS. 9411) will now be described, in conjunction with FIG. 13 of the drawing. As before, at the beginning of a dwell period of the Vitaline mold conveyor C, compressed air is delivered through line 122 and moves spool 124 of valve 126 to the left, the control line 172 on the opposite end of spool 124 from control line 122 being vented to the atmosphere via exhaust port 171 of limit valve 1'70. The pressurized air in conduit 110 is then channeled through valve 126 into conduit 151 and against the rod side of the piston '6, causing piston 56 to be moved into cylinder 52, and the carriage 34 to be extended toward the fill station, placing the nozzles 66 in the molds M at the fill station. When carriage 34 leaves its retracted position the operator 130 of valve 140 is released, and the safety interlock is put into operation as before. When carriage 34 is fully advanced it contacts and depresses operator 148 of limit valve 132, and this communicates supply conduit 110 with control conduit 128 leading to the right end (as pictured) of the control spool 164 for control valve 166. The opposite end of spool 164 is vented to the atmosphere via conduit 172 and exhaust port 171 of valve 170. Hence, spool 164 is moved to the left, putting supply conduit 110 into communication with both control line 150J leading to the rod side of piston 82, and control line 174 leading to the bare side of closure plate piston 96. Piston 182 is retracted and piston 96 is extended, causing simultaneous advancement of the feed rams 74 and closure of the ram cavities by closure member 86. When the rams 74 have been fully advanced (FIGS. 9 and member 70 contacts and depresses operator 168 of limit valve 170, and this communicates supply conduit 110 with control line 172. At this point of `time the Vitaline advance-dwell valve 102 has functioned to vent Vitaline control line 106, and hence feeder control line 122, to the atmosphere via exhaust port 108. Thus, the higher pressure in control line 172 functions to move valve spool 124 of valve 126 and valve spool 164 of valve 166 to the right and into the position pictured in FIG. 13. This move reverses the direction of pressure differential on piston 56, causing the feed carriage 34 to retract. Then, once operator 148 is released, the direction of pressure differential on pistons 92 and 82 is reversed, and simultaneously there is an extension of piston 82, and hence a retraction of the rams 74', and an opening of the closure plate |86.

By way of typical and therefore nonlimitive example, FIG. l2 shows a stick-embedded, non-refrigerated food product manufactured according to the present invention. It is shown to comprise a main body portion 206, which may be a solidified mixture of dried cereal and suitable binder (of the type heretofore described), for example, and a core (e.g. a Carmel) of a different food material into which a stick or handle 210 is embedded.

Referring to FIGS. 9-11, when carriage 316 is fully advanced nozzles 66 extend part way into the molds M, and the prong 204 (or 204') extends a substantial distance into the mold M. The position of prong 204 remains fixed as the rams 74 are advanced. Thus, the mix from hopper 22 is injected into the mold M in the space surrounding and forwardly of the prong 204. The mix is stiff enough that a cavity is left when the prong 204 is withdrawn from the mold M as the carriage 34 is retracted. The caramel or other filling 208 is deposted into the cavities left by the prongs 204 during another dwell and at another station between the fill and stick insertion stations. In addition to adding more flavor to the product FP, the core material 208 may function as a cement for firmly securing the stick or handle 210 to the main ingredient 206 of the food product FP.

From the foregoing discussions of various operating techniques and equipment constructions characteristic of the invention, various further modifications and adaptations thereof will occur to those skilled in the art to which the invention is addressed, such as related in the following discussion, simply by way of further example.

As to the feeder mechanism, it will be understood the product delivery nozzles can be arranged vertically when the feeder is utilized with an equipment involving an essentially horizontal path of travel of the molds, such as the Gram type automated confection forming equipment. The feeder mechanism can also be formed as an integral part of the confection forming equipment, being supported thereby, or from the building structure above the equipment, as desired. With respect to the configuration of the closure plate and component closure bars for enclosing the ram cavities, the configuration of the closure bars can take any desired form, such as a reversal of the slope of the edges thereof from the form shown. As a further variation with respect to how the product mix can be segregated in the ram cavities, the ram cavities if desired can be of essentially cylindrical form, operated in conjunction with rotatable closure sleeves in lieu of a reciprocated closure plate.

As to applications of the type of feeder mechanism herein disclosed, and with respect to use thereof in conjunction with equipment other than the Vitaline type of equipment illustrated, the feeder mechanism can be employed to `deliver successive, measured amounts of the plastic conglomerate mix to any desired product convey ing means, such as to a `flat conveyor belt, such as in the manner of the feeder mechanism disclosed in Anhanger et al. -U.S. Pat. No. 3,203,037, or to a series of trays.

As to variations in the automated forming equipment to which the food mix is dispensed, it will be understood the molds employed can tbe of any desired cross section configuration, or of any suitable material other than stainless steel, reinforced plastic molds being adequately heat conductive to be suitable in some instances. Also, in any given installation, an increase in the number of molds per row or set oftentimes can be effected, to greatly increase the productivity of the equipment, in view of the relatively shorter solidification time requirement when forming products which need not be stored under refrigeration, as compared with the freezing time requirement of such equipment when forming frozen confections. As a further variation, rather than utilization of embedded sticks which remain with the formed products, so-called stickless type products can be molded by the technique of the present invention by use of so-called pin racks, with pin extraction prior to packaging. Variations are also possible with respect to the manner of heating the molds to release the solidified products therefrom, such as use of infrared heating in lieu of dip type mold release tanks. Yet another variation with respect to the form of the molded product can involve formation of a cavity within the product as it is solidifying, by a vertically reciprocated piercing die which partially enters each mold, after which the formed cavity can be lled with a food mix of another constituen- Cy.

What is claimed is:

1. The method of making a non-refrigerated, molded food product of solid form and comprising a uncooked binder of uniform consistency throughout, comprising:

(a) feeding a conglomerate food mix into and through a mixing zone, which mix is characterized by an essentially solid state at room temperature and exhibiting plastic ow when heated to above bod)l temperature;

(b) heating the conglomerate mix to a temperature in the range of from about 100 F. to about 130 F. while feeding such through the mixing zone to keep the mix in plastic state and of uniform constituency;

(c) mechanically and positively injecting a measured amount of the plastic conglomerate mix into each mold of an automated molding device;

(d) cooling the plastic conglomerate mix in each mold at reduced temperature and for a period of time sufficient to rapidly effect a complete solidification thereof;

(e) briefly heating each mold to release the formed and solidified food product therefrom; and

(f) removing the formed food products from the molds.

2. The method of claim 1, further comprising inserting a stick into the mix in each mold prior to solidification thereof.

3. The method of claim 1, further comprising applying a coating to each formed food product promptly after removal thereof from its mold.

4. The method of claim 3, comprising maintaining the interior of each formed product cold during removal thereof from its mold, and applying a dip coating to each formed food product promptly after removal thereof from its mold.

5. The method of making a non-refrigerated molded food product of solid form and comprising an uncooked binder of uniform constituency throughout, comprising:

(a) feeding a conglomerate food mix into and through a mixing zone, which mix is characterized by an essentially solid state at room temperature and a state of plastic tiow at temperatures above body temperature, the basic ingredients of said mix being particulated solids and the uncooked binding agent;

(b) heating the conglomerate mix to a temperature in the range from about 100 F. to about 130 F., while feeding such through the mixing zone to keep the mix plastic`and of uniform constituency;

(c) mechanically and positively injecting a measured amount of the heated plastic conglomerate mix into each mold of an automated molding device;

(d) cooling the plastic conglomerate mix in each mold to effect a complete solidification thereof in a time of less than about eight minutes;

(e) heating each mold to release the formed and solidified food product therefrom; and

(f) removing the formed food products from the molds.

6. The method of claim 5, further comprising inserting a stick into the mix in each mold prior to solidification thereof.

7. .The method of claim 5, further comprising applying a coating to each formed food product promptlyafter removal thereof from its mold.

8. The method of claim 7, comprising immersively applying a thin chocolate coating to each formed food product while the interior thereof is at substantially less than room temperature.

9. The method of claim 5, further comprising inserting a stick into the mix in each mold prior to solidifcation thereof, and applying a coating to each formed food product promptly after removal thereof from its mold.

10. The method of making a non-refrigerated, molded food product of solid form, comprising:

(a) feeding a conglomerate food mix into and through a mixing zone, which mix includes as part thereof a fragile, particulated solid ingredient and an uncooked fluid binding agent which is characterized by an'essentially solid state at room temperature and an essentially fluid state at temperatures above body temperature;

(b) heating the conglomerate mix to a temperature in the range from about F. to about 130 F., while feeding such through the mixing zone to keep the mix plastic and of uniform constituency;

(c) non-destructively injecting a measured amount of the heated plastic mix into each mold of an automated molding device without crushing the said fragile solid ingredient;

(d) cooling the plastic conglomerate mix in each mold to rapidly effect a complete solidification thereof;

(e) briefly heating each mold to release the formed and solidified food product therefrom; and

(f) withdrawing the formed food products from the molds.

11. The method of claim 10, wherein said uncooked fluid binding agent at least principally comprises 'vegetable oil having a iiow point of about 96 F., sugar, and nonfat milk solids.

12. The method of claim 10, wherein said fragile, particulate solid ingredient consists essentially of puffed or toasted cereal.

References Cited UNITED STATES PATENTS 2,278,466 4/ 1942 Musher 99-1 3,271,813 9/1966 Gernandt 99-107 2,651,573 9/1953 Leach 99-134 1,952,688 3/ 1934 Schnaier 107-54X 2,217,700 10/ 1940 Musher 99-137 2,801,922 8/1957 Oprean 99137 3,031,978 5/ 1962 Rasmusson 107-8 U.S. Cl. X.R. 

